Ingot mold with chilled matrix walls and apparatus for making same



Feb. 18, 1930; J. E. PERRY 1,747,679

.INGOT MOLD WITH GRILLED MATRIX WALLS AND APPARATUS FOR MAKING SAME F'iLed Jul3, 3, 1926 3 Sheets-Sheet l w INVENTOR J0fi72 E. l erry ATTORNEY Feb. 18, 1930-. J. E. PERRY 1,747,679

INGOT MOLD WITH CHILLED MATRIX WALLS AND APPARATUS FOR MAKING SAME Filed July 3, 1926 3 Sheets-Sheet 2 TORNEY HII V /7 R r m m E .N. 5 A n 1 5 j; Z

L w m d E 4 ,1... 1 m a w Feb. 18, 1930.

J. E. PERRY INGOT MOLD WITH GRILLED MATRIX WALLS AND APPARATUS FOR MMQING 'Filed July 5, 1926 3 S heets -Sheet 3 Patented Feb. 18, i930 -UNITED STATES PATENT. OFFICE JOHN E. PERRY, OF SHARON, PENNSYLVANIA, ASSIGNOR TO VALLEY MOULD AND IRON CORPORATION, YORK OF SHARPSVILLE, PENNSYLVANIA, A CORPORATION OF NEW INGOT MOLD WITH CHILLED MATRIX \VALLS AND APPARATUS FOR MAKING SAME Application filed Ju1y 3 1926. Serial No. 120,280.-

- comprising a core bar covered with a thick layer of mold sand. This sand formed the core surface and would crumble when the 'core bar was stripped from the solidified mold, thereby relieving the stress and strain on the mold during the stripping operation. These sand walls of the core, having a relatively low rate of heat conductivity, tended to retain the inner or matrix walls of the ingot mold cast in such set-up in a nonchilled condition so that the inner or matrix faces of the ingot mold walls comprised relatively open grained cast iron. This inner wall, due-to the sand on the core, was always more or less roughened, and being of soft open grained metal, tended to cut away relatively rapidly'whe'n subjected to or struck by a flowing stream of molten steel.

The present invention overcomes the diflieulties of the known art by providing a metal core having metal faces adapted to be brought directly into contact with the molten iron when the ingot mold is being cast. These metal faces of the core being good conductors of heat, rapidly chill the molten iron adjacent the core and thereby produce chilled metal faces on the matrix portion of the ingot mold cast in this new set-up. Such an ingot mold cast against a cold metal core has fine grained metal adjacent the matrix surface which is very smooth and hard because of having been cast against a smooth metal chill surface. molten iron adjacent the cold metal .core

tends to assume nodular or spherical forms while the molten iron is freezing. This is one factor in producing the fine close gram in the solidified metal, which is very resistant -to erosion from the hot stream of molten steel while an ingot is being poured, and which also tends to delay fire cracking ofthe ingot mold due to successive heats while in use.

The preferred form of core, according to the )resentinvention, comprises a core member ormed of a plurality of metal side plates The graphitic carbon in the constructed in such manner as to be collapsible, and thereby occupy. a lesser space when collapsed than when full open, so that the collapsed core member may be easily withdrawn after the mold is cast. Furthermore,

thejoints between the plates on said core are arranged on the side faces in such manner as to comprise straight longitudinal lines, so

that any slight ridge left by said joints onthe matrix face of the ingot mold will produce a. very slight groove 011 the ingot, which does not interfere in any way with stripping operations or with the fabrication of the ingot. The movable side plates of the core are controlled in such manner that certain of the side plates initially move inwardly, while others of the side plates are held stationary in order to permit the edges of the moving plates to pass the edges of the initially stationary plates to provide clearance for the inward movement of all said side plates as the core is collapsed.

It is realized that the present invention may be embodied in constructions other than those herewith specifically disclosed. T herefore, it is desired that this disclosure be considered as illustrative and not in the limiting sense.

Fig.1 is an elevational view of a set-up for casting ingot molds in accordance with the presentinvention and illustrating a portion of the set-up in section.

Fig. 2 is an elevational sectional view through an ingot mold cast in accordance with the present invention.

8 is an elevational sectional view through a collapsible core in accordance with the present invention and taken on the line of Fig. 5.

l is an elevational sectional view-of a core in accordance with the present invention taken on line el-4 of Fig. 5.

Fig. 5 is a sectional view taken on line Fig. Gis a view similar to Fig. 5 but showing the relation of the plates when the core is collapsed.

Referring now, to the drawings and more particularl to Fig. 1. the flask 1 is set in the usual manner upon a base plate 2, and the flask carries the usual side wall 3 of rammed sand. The base plate preferably is recessed to receive the bottom 4 of: the metal core 5' in such manner that the side plates 'of the metal core rest on the face of the base plate and form a metal to metal joint at this'juncture. However, the bottom of the matrix 6' of the set-up maybe sand faced where it .bar 8, which carries pairs of control plates 9, and 10 arranged at substantiallyright angles.

to each other, since the core is substantially rectangular 'in cross section. These control plates extend through slotted openings 11 and 12 in the-tube 7. r The control plates 9 are provided with full inclined cam slots 14 that enclose rivets 15 extending between the arms 16 which are integral with the side plates 17., Preferably, theside. plates 17 are recessed as at 18 to form clearance spaces ,for the ends of the control plates 9. From the construction just described, it will appear that if the parts are in position showni'n F igure3 and the controlbar 8 be forced downwardly, the action of the cam slots 14 on the rivets 15' will caus'ethe side plates 1? to move inwardly toward the axis of the controlbar.

Referring now to Fig. ,4, it will be observed that the control plates 10 are provided with double cam slots having a vertical portion 19 and a short inclined portion 20. Also, that:

these slotscooperate with rivets 21 extending between the arms 22 carried by the side plates 24, and that the sideplates 24 are re- F cessed at 2'5 to'form-clearance spaces for-the ends of the control plates '10. Assuming the partsto be in the position shown'in Fig. 4 and that the control bar 8 be forced downwardly, it will be observed thatso long as the rivets 21 are in the vertical portions 19 of the cam slots, that the side plates 24 will i be stationary,'but that as soon as the rivets 21 encounter the inclined portions 20. of the cam slots, the sideplates 24 will moveinwardly. 4

Considering Figs. 3, 4, 5, and 6, it will be observed that with the parts in positions shown in positions 3, 4'. and 5, and the con-- trol bar 8 then forced:- downwardly, the side plates 17 will move inwardly until the edges of the side plates 17clear the edges of the.

side plates 24. "At this time the rivets 21 will encounter the short inclined portion 20 of the control plates 10 and now the side-plates v 24 will start to and continue to move mwardly coincident. with the continued inward movement of the'side platesl7, until in their final innermost position, the plates will occupy the relation illustrated in Fig.

6. The expanded periphery of the core is indicated inFig. 6 by the dotted line 26, and

it will be observed that the-side plates, when collapsed, are .well within the lines represented by the dotted line 26 so that the core- I can easily be removed from the solidified ingot mold.

. The bottoms 27 of the side plates are preferably machined. to form a metal to metal joint with the base plate 2 when the core is in position in the set-up, althoughwhere desired a sand floor' may beprovided on the base plate.

The'side plates 17 and 24 may comprise any suitable chill material, but preferablycomprise cast-iron; and the outer faces of theseside plates are preferably smooth so that when the core is expanded, a very smooth continuous periphery of the shape desired is provided so that a smooth matrixis formed on the ingot mold cast within this setup. Preferably, suflicient weight of metal is provided in the sid plates of the core member to.

effectually-chill the hot .molten iron cast against t se-side plates. The thickness of metal in these side plates prevents burning sired chill on the ingot mold. cast against these chilling'merfibers.

Preferably, the top' of the core member is covered by a top plate 28, and the control bar 8-1r'1ay be slotted to receive a key 29 which bears on the top plate 28 to retain the core in expimded relation. The key 29 is driven out when it is desired to collapse the core.

Airingot mold cast in accordance with the present invention comprises cast iron side walls A and a matrix B, with the metal at C, comprising the surface of the matrix walls, and also the metal adjacent thereto being chilled. This chilling of the metal at C protimes a close fine grained structure with the graphitio carbon. in nodular or spherical form and with the surface of the matrix wall extremely smooth and dense, while theremainout of the side plates and produces the dey ing portion of the side walls oi the ingot mold are of a softer more open crystalline structure'of a less friable nature than the chilled portion. The hard chilled surface re sists erosion from the hot steel poured in the f mold and also resists fire cracking while the condition of the metal in'the body oftho side wall'produces strength and elasticity required in ingot molds.

The molten iron used for casting the ingot mold comprising the present invention may be. suitable iron adaptable for this purpose, but preferably comprises molten iron direct from the blast furnace. Such-molten iron is iron in direct metal carries a large content mold.

- metal tends to throw out the free carbon as 'taining "changed to a dense close grain with the free free carbon which comprises chilling the hot known as direct metal and the uncombined adapted to form the matrix of said ingot of free or graphitic carbon as well as some 7. The method of casting ingot moldsiron carbides, all of which is mixed in the which comprises chilling'the matrix .sideof molten mass. As such a mass. freezes the the mold ,walls during casting andmainthe outer side of said mold wallsun 7 graphite flakes; but where such metal is chilled. 4 chilled rapidly whilefreezing the character 8. The method of castingingot molds from of the frizen massadjacent ,the chill is direct metal containing a large content of or graphitic carbon in nodular or spherical metal adjacent the matrix side of the mold form, interspersed with uncombined iron and walls during casting and maintaining the hot hard and brittle and this dense crystalline unchilled.

an increased amount of.combined iron and metal adjacent the outer side of said mold carbon, or iron carbide. The frozen mass rewalls unchilled. 4

mote from the chilled portion is of a more 9, The method of casting ingot molds comopen crystalline structure contairiingfree or prising chilling the matrix side of the walls graphitic carbon in flake form and a lesser of the ingot molds throughout their length amount of iron carbide and a larger amount during the casting operation while maintain-' of uncombined iron. The chilled portion is ing the remaining portion of the ingot mold structure blends into asofter tougher and 10. The method of casting ingot molds more malleable unchilled metal comprising. 'from direct metal comprising chilling the mamold.

i 'aningot mold ast from direct metal with a large content 0 free carbon and having the' trix side of the walls ofthe ingot molds to a uniform depththroughout their length during the casting operation while maintaining the remaining portion of the ingot mold unchill d. a j

.' JOHN E. PERRY.-

the supporting cast iron body ofthe ingot (Having Iclaimisf g 1 An'article of-manufacture comprising thus described my invention, what 90 metal adjacent the surfaces'comprisiiig the matrix of the mold chilled to substantially a uniform depth over a portion of the matrix of the mold and with the outer portions of the ingot mold walls cast iron. 2. An article of manufacturecomprising an ingot mold of cast iron with the graphitic carbon in the cast iron adjacent the matrixface .of the mold being in nodular form and with the outer portions ofthe ingot mold wallscomprising cast iron with the graphitic carbon therein in flake form.

3. An article oflmanufacture comprising an .ingotmold of cast iron cast from direct metal with a large contentof graphitic carbon contained therein -with' the graphitic comprising unchi'lled 'carbon in the cast iron adjacent the matrix face of the mold being in nodular form and with the outer portions of the ingot mold walls comprising cast iron with the, graphitic carbon therein in flake form.

4. A set-up for casting an ingot mold comprising, in combination a sand mold for the outer portions of said ingot mold, and a chill v core to form the matrix of said ingot mold.

5. A set-up for casting ingotmolds coniprising in combination a flask carrying a sand wall to determine the exterior shape of the ingot mold, and a collapsible chill core forming the matrix of said ingot mold. 1

, 6. A set up for casting ingot molds, said 1 7 set-up comprising in combination, a bottom J plate, a flask having sand sid'e walls set on said bottom plate, and a chill core forming a metal joint with said bottom plate and being 13o 

